Folding carton



April 18, 1967 H. w. FORRER FOLDING CARTON 2 Sheets-Sheet 1 Filed Aug. 2, 1965 R 0 R T E R R V 0 F W R E M O H ATTORINEY A ril 18, 1967 H. w. FORRER 3,314,535

FOLDING CARTON Filed Aug. 2, 1965 2 Sheets-Sheet 2 INVEINTOR HOMER W. FORRER ATTO RiN EY United States Patent 3,314,585 FOLDHNG CARTON Homer W. Forrer, .loneshoro, Ga, assiguor to The Mead Corporation, a corporation of Ohio Filed Aug. 2, 1965, Ser. No. 476,414 8 Claims. (Cl. 229-16) This invention relates to folding cartons and more particularly to end closure structure for a folding carton tray formed from a 4-paneled tubular structure and to which a telescoping cover may be readily applied in accordance with one facet of the invention.

It is customary at the present time to package certain items such as collapsed cartons, carton blanks and similar items in corrugated containers. Such containers are normally well adapted for heavy duty service and ordinarily are loaded through one open end. Where variations in thickness of the packaged product occur due to humidity and temperature conditions or for some other reason, it may be diflicult to achieve uniform quantities of the packaged items and at the same time to avoid having empty space within the container where conditions result in shrinkage and a minimum size of the individual items which are to be packaged.

One object of this invention is to provide an improved folding carton type container for such items as collapsed folding cartons and blanks thereof and wherein the container is adaptable to variations in the unit size of the packaged product.

Another object of this invention is the provision of a folding carton type container wherein end closure structure is arranged which is unusually sturdy and yet which does not require the application of glue, staples or the like.

A folding carton constructed according tothis invention may constitute a tray portion and a telescopic related cover portion, the tray portion being formed from a four-sided tubular structure in which the end closure structure is struck from one panel and foldably joined by web structure to the opposed side panel, together with a retaining panel foldably joined to opposite ends of the bottom panel of the tray and held at its ends by gussets which interconnect the retaining flaps with anchor panels foldably joined to the opposite ends of the end walls and wherein the anchoring flaps and gussets are captured between the side wall and the web structure which holds the end panels in place. Preferably, the cover is arranged so that the cover side panels are disposed exteriorly of the mid portions of the upper edges of the side walls and interiorly of the end portions of the side walls. This telescoping relationship renders the carton, according to this invention, readily adaptable to variations in the size of the packaged unit.

For a better understanding of the invention, reference may be had to the following detailed description taken in conjunction with the accompanying drawings in which FIG. 1 is a perspective view of the tray portion and cover portion of the carton with the cover removed; FIG. 2 is a perspective view of a container constructed according to this invention with the cover mounted in closed position; FIG. 3 is a perspective view of the tray portion only of the container and depicting the container in partially assembled condition; FIG. 4 is a perspective view of the tray portion only of a container constructed according to the invention and depicting the tray portion in tubular form before any of the assembly folding operations have been performed; FIG. 5 is a plan view of a blank from which the tray portion of the container is formed; and in which FIG. 6 is a plan view of a blank from which the cover portion of the container is formed according to this invention.

With reference to the drawings, the numeral 1 generally designates the cover portion of the container, while the numeral 2 generally designates the tray portion of the container. As is best shown in FIGS. 1 and 6, the cover portion 1 comprises a main cover panel 3 and a pair of cover side panels 4 and 5 which are foldably joined to the side edges of main cover panel 3 along fold lines 6 and 7, respectively.

The tray portion of the carton comprises main panel 8 to the end edges of which a pair of retaining flaps 9 and 10 are foldably joined along fold lines 11 and 12, respectively. A first side panel 13 is foldably joined along side edge 14 to main panel 8. A pair of anchoring flaps 15 and 16 are foldably joined along fold lines 17 and 18 to the end edges of side panel 13. A gusset 19 is foldably joined along line 20 to an end edge of retaining flap 9 and is also foldably joined along diagonal fold line 21 to the adjacent end of anchoring flap 15. Similarly, gusset 22 is foldably joined along fold line 23 to an end of retaining flap It and the gusset 22 is toldably joined to the adjacent end of anchoring flap 16 along diagonal fold line 24.

A pair of web structures generally designated at 25 and 26 are struck from side panel 13 and are foldably joined thereto along diagonal fold lines 27 and 28, respectively. Preferably, though not necessarily, web structures 25 and 26, respectively, constitute a pair of triangles designated by the numerals 29, 30, 31 and 32. Web structures 25 and 26, respectively, constitute a pair of triangular panels 29 and 30 foldably interconnected along fold line 33 and similar panels 31 and 32 foldably interconnected with each other along fold line 34.

The web structures 25 and 26 serve to hold one end of the end panels 35 and 36 in end closing positions. Thus, as is apparent particularly in FIG. 5 end panel 35 is foldably joined to web structure 25 along fold line 37, while end panel 36 is foldably joined to web structure 26 along fold line 38.

Preferably, the upper and lower edges of the end panels are provided with sealing flaps. Such flaps are effective in excluding extraneous foreign matter from the interior of the carton such as dust, for example. In the drawing sealing flaps 39 and 40 are foldably joined to the end panel 35 along the fold lines 41 and 42, respecively. Simillarly, sealing flaps 43 and 44 are foldably joined to the end panel 36 along the fold lines 45 and 46.

Web structure is provided on the opposite side edges of the end panels 35 and 36 and in the drawings, such structure is generally designated by the numerals 47 and 48. Web structure 47 is foldably joined to a side edge of end panel 35 along fold line 49. As has already been explained, the web structures 47 and 48 may constitute a pair of triangular areas designated in the drawings by the numerals 50 and 51. Areas 50 and .51 are foldably connected along fold line 52.

Web structure 48 is foldably joined to end panel 36 along fold line 53 and, as explained, may constitute a pair of triangles 54 and 55 which are foldably joined along fold line 56.

Web structures 47 and 48 in effect are struck from side panel 57 and are foldably joined thereto along diagonal fold lines 58 and 59.

Side wall 5'7, like side wall 13, is provided with anchoring flaps and in the drawings these anchoring flaps are designated by the numerals 6i) and 61. Anchoring flap 60 is foldably joined to an end edge of side wall 57 along fold line 62, while anchoring flap 61 is foldably joined to the other end edge of side wall 57 along fold line 63.

A pair of gussets 64 and 65 are foldably joined to the ends of anchoring flaps 6t) and 61 along fold lines 66 and 6'7, respectively.

For the purpose of forming a tubular structure such as is depicted in FIG. 4 from the blank depicted in FIG. 5, a. securing flap designated by the numeral 68 is foldably joined along fold line 69 to an edge of side panel 57 and to the triangular shaped gussets 64 and 65 as is shown in FIG. 5.

In order to form the tubular sleeve depicted in FIG. 4 from the blank depicted in FIG. 5, it is simply necessary to apply glue or other suitable securing means to the securing flap 68 and then to affix that flap to the left hand edge of main panel 8 as viewed in FIG. 5.

The first step in forming the end closure structure for the carton is depicted in FIG. 3. Thus, the anchoring flaps 16 and 61 at one end of the carton are simply swung inwardly along their respective fold lines 18 and 63 to occupy positions of fiat contacting relation to the inner surfaces of the side panels 13 and 57. Of course, the gussets 22 and 65 serve to hold the retaining flap in the vertical position as is clearly shown in FIG. 3. Simultaneously, the sealing flap 44 is folded over toward the right along its fold line 46, if desired. It will be understood that for certain applications of the invention, it would be desirable not to fold the sealing flap 44 but to complete loading of the carton and then to fold the flap 44 into the position depicted in FIG. 3. The retaining flap 9 is folded into its upright position simultaneously with the folding of the retaining flap 10 preferably and during this operation the anchoring flaps and 60 are simply swung inwardly along their fold lines 17 and 62, it being understood that the ends of the securing flaps 68 are afiixed to the ends of the retaining flaps 9 and 10 by any suitable means such as glue. Of course, it will be understood that the sealing flap 39 might be left in the position shown in FIG. 4 rather than folded over as depicted in FIG. 3, if desired.

Upon completion of the step depicted in FIG. 3, the carton is then folded so that the parts occupy the position generally designated by the numeral 2 in FIG. 1. Thus, and with reference to FIGS. 1 and 3, the end panels 35 and 36 are simply forced downwardly into the vertical positions depicted in FIG. 1. During this operation, of course, the end panel 35 is held in the vertical position by the web structures 27 and 47 which lie immediately adjacent the gussets 19 and 64. Thus, in accordance with one feature of the invention, the end closure structure of the carton is not usually sturdy and without requiring an application of glue to hold the end panels such as 36 and 35 and the retaining flaps such as 9 and 10 in place. Thus, the gussets 19 and 64- and their associated anchoring flaps 15 and 60 are captured between the side panels 13 and 57, respectively, and the web structures and 47, respectively.

In like fashion, at the other end of the carton, an end closure structure constitutes the end panel 36 together with the retaining flap 10. Similarly, the anchoring flaps 16 and 61 together with gussets 22 and 65 are captured between the side panels 13 and 57 and the associated web structures 26 and 48.

The bottom edge of the carton forming the junction between the end panels and 36 and the bottom or main panel 8 is secure against entry of external foreign matter because of the sealing flaps 4t! and 43 which lie in flat face contacting relation to the ends of the main bottom panel 8.

As already pointed out, the sealing flaps 39 and 44 may be secured in flat face contacting relation to the inner surfaces of the end panels 35 and 36, respectfully, if desired and as indicated in FIG. 1. If one the other hand, these flaps are desired to serve as sealing flaps for the upper ends of the end panels 35 and 36, they may simply be left in the positions indicated in FIG. 3.

A carton constructed according to this invention is particularly well adapted for use under changing conditions whereby the size of the packaged items vary somewhat. For example, with items stacked into the tray portion of the carton as, for example as depicted in FIG. 1, the cover portion 1 is adapted to move vertically and thereby to accommodate larger and smaller items. The cover side panels 4 and 5 of the cover 1 may be arranged so that they occupy the notches 25a, 26a and 47a, 48a, respectively, as shown in FIG. 2 with the mid-portion of cover side panel 5 disposed outside the portion of side panel 57 which is between the notches 47a and 48a. Prefe'rably, the ends of cover side panel 5 are disposed interiorly of the portions of side panels 57 which are adjacent the ends of the carton as is shown, for example, in FIG. 2. Of course, cover side panel 4 would be arranged in a manner identical to the arrangement of cover side panel 5 with respect to the side panel 13. Of course, side panels 4 and 5 can be disposed completely inside the side panels 13 and 57 and in this manner the cover may occupy lower positions and thereby engage the top-most item even when the packaged items do not completely fill the tray portion 2.

From the foregoing description, it is apparent that the end closures of the carton are particularly sturdy and without requiring glue or stapling due primarily to the snug co-action between the anchoring flaps such as 16 at 61 at one end of the carton and their associated gussets 22 and 65 as being captured between the adjacent ends of the side panels 13 and 57 and the adjacent web structures 26 and 48. Likewise, the other end of the carton is of a similar sturdy construction. Furthermore, the telescoping arrangement of the cover panel 1 and its particular interrelationship with the notches such as 47a and 48a, 25a and 26a, renders the carton particularly adaptable for changes in the sizes of the packaged product.

While a particular embodiment of the invention has been shown and described, it is not intended that the invention be limited to the particular arrangement as disclosed and intend in the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the invention.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. Carton end closure structure comprising a main panel, a pair of side walls foldably joined respectively to opposite side edges of said main panel, a pair of anchoring flaps foldably joined respectively to corresponding end edges of said side walls, a retaining flap foldably joined to the adjacent end edge of said main panel, a pair of gussets foldably interconnected with each end of said retaining flap and respectively connected folda'bly with the adjacent ends of said anchoring flaps, web structure foldably connected along diagonal fold lines with an edge of each of said side walls, and an end panel foldably joined respectively along its side edges to said web structure, said anchoring panels being disposed in fiat face contacting relation with the inside surfaces of their associated side walls so as to hold said retaining flap in generally perpendicular relation to said main panel and said web structures being disposed respectively in flat face contacting relation with the inside surfaces of said gussets so as to capture said gussets between said web structures and said side walls respectively thereby to hold said end panel in secure perpendicular relation to said main panel.

2. Carton end closure structure according to claim 1 wherein a sealing flap is foldably joined to opposite edges of said end panel.

3. Carton end closure structure according to claim 1 wherein each web structure comprises a pair of generally triangular panels foldably connected with each other.

4. A carton comprising a main bottom panel, a pair of side walls foldably joined to said main panel along opposite side edges, end closure structure at each end of the carton, a pair of notch-like formations in the top edge of each of said side Walls, a main cover panel, and a pair of cover side panels foldably joined to said cover main panel along opposite side edges thereof, said cover side panels being telescopically related with said side walls and each being disposed in said notches with their middle portions disposed in exterior relation to the portions of said side Walls which are between said notches and with the end portions of said cover side panels disposed inside the end portions of said side walls.

5. A carton according to claim 4 wherein a pair of sealing flaps are foldably joined respectively to the edges of said end closure structure which are remote from said main panel, said sealing flaps being captured between the carton contents and the inner surface of said cover main panel at each end thereof.

6. A carton blank comprising a main panel, a pair of retaining flaps foldably joined respectively to the end edges of said main panel, a first side panel foldably joined to one side edge of said main panel, a pair of anchoring flaps foldably joined respectively to the end edges of said first side panel, a pair of gussets foldably connecting one end of each of said anchoring flaps and the adjacent end of the adjacent retaining flaps, a first pair of web structures struck out of said first side wall and foldably joined thereto along diagonal fold lines, a pair of end panels foldably joined respectively to said web structures along corresponding side edges of said end panels, a second pair of web structures foldably joined respectively to said end panels along edges thereof remote from said first web structures, a second side panel from which said second web structures are struck and to which said second web structures are foldably joined along diagonal fold lines, a second pair of anchor panels foldably joined to the end edges of said second side panel, and a second pair of gussets foldably joined respectively to the ends of said second pair of anchoring flaps remote from said end panels.

7. A blank according to claim 6 wherein a securing flap is foldably joined to the edge of said second side panel remote from said second web structure and to said second pair of gussets.

8. A blank according to claim 6 wherein a pair of sealing flaps are foldably joined respectively to opposite edges of said end panels other than the edges thereof which are joined to said first and second pair of web structures.

References Cited by the Examiner UNITED STATES PATENTS 1,357,519 11/1920 Russell 229- 2,540,065 1/1951 Williamson 229-52 XR 2,595,678 5/ 1952 Lenkofr- 229-43 2,630,265 3/1953 Hellawell 229-41 2,679,970 6/1954 Saidel 229-27 2,690,866 10/ 1954 Kirby 229-28 3,170,615 2/1965 Mortenson 229-30 X FOREIGN PATENTS 736,218 9/1955' Great Britain.

JOSEPH R. LECLAIR, Primary Examiner. D. T. MOORHEAD, Assistant Examiner. 

1. CARTON END CLOSURE STRUCTURE COMPRISING A MAIN PANEL, A PAIR OF SIDE WALLS FOLDABLY JOINED RESPECTIVELY TO OPPOSITE SIDE EDGES OF SAID MAIN PANEL, A PAIR OF ANCHORING FLAPS FOLDABLY JOINED RESPECTIVELY TO CORRESPONDING END EDGES OF SAID SIDE WALLS, A RETAINING FLAP FOLDABLY JOINED TO THE ADJACENT END EDGE OF SAID MAIN PANEL, A PAIR OF GUSSETS FOLDABLY INTERCONNECTED WITH EACH END OF SAID RETAINING FLAP AND RESPECTIVELY CONNECTED FOLDABLY WITH THE ADJACENT ENDS OF SAID ANCHORING FLAPS, WEB STRUCTURE FOLDABLY CONNECTED ALONG DIAGONAL FOLD LINES WITH AN EDGE OF EACH OF SAID SIDE WALLS, AND AN END PANEL FOLDABLY JOINED RESPECTIVELY ALONG ITS SIDE EDGES TO SAID WEB STRUCTURE, SAID ANCHORING PANELS BEING DISPOSED IN FLAT FACE CONTACTING RELATION WITH THE INSIDE SURFACES OF THEIR ASSOCIATED SIDE WALLS SO AS TO HOLD SAID RETAINING FLAP IN GENERALLY PERPENDICULAR RELATION TO SAID MAIN PANEL AND SAID WEB STRUCTURES BEING DISPOSED RESPECTIVELY IN FLAT FACE CONTACTING RELATION WITH THE INSIDE SURFACES OF SAID GUSSETS SO AS TO CAPTURE SAID GUSSETS BETWEEN SAID WEB STRUCTURES AND SAID SIDE WALLS RESPECTIVELY THEREBY TO HOLD SAID END PANEL IN SECURE PERPENDICULAR RELATION TO SAID MAIN PANEL. 